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HOMESERVICE MANUALSCHEVROLET2008CHEVY EXPRESS G2500, VAN CARGO, 6.6 6REPAIR AND DIAGNOSISENGINE MECHANICALCOOLING SYSTEM (MECHANICAL)ENGINE COOLING SYSTEMREPAIR INSTRUCTIONSRADIATOR REPLACEMENT (DIESEL)REMOVAL PROCEDURE
2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6

Removal Procedure

2008 Chevrolet Chevy Express G2500, Van Cargo, 6.6 6SECTION Removal Procedure
IMPORTANT: Always install a new set of insulators when replacing a radiator. Used insulators may be worn or too large for the new radiator. These conditions may cause the new radiator to be loose.
    Fig 1: Identifying Air Cleaner Assembly
    GM1726280Courtesy of GENERAL MOTORS CORP.
  1. Remove the air cleaner assembly. Refer to Air Cleaner Assembly Replacement .
  2. Remove the upper radiator baffle.
  3. Remove the surge tank. Refer to Radiator Surge Tank Replacement .
  4. Remove battery. Refer to Battery Replacement (Primary) or Battery Replacement (Secondary) .
  5. Remove the charged air cooler inlet hose/pipe. Refer to Charged Air Cooler Hoses/Pipes Replacement (Inlet) or Charged Air Cooler Hoses/Pipes Replacement (Outlet) .
    6. Fig 2: View Of Radiator Inlet Hose
    GM834215Courtesy of GENERAL MOTORS CORP.
  6. Remove the clamp at the radiator inlet using the J 38185  . See Special Tools .
  7. Remove the radiator inlet hose (5) from the radiator.
  8. Remove the outlet heater hose clamp at the radiator using the J 38185  . See Special Tools .
  9. Remove the outlet heater hose (2) from the radiator.
  10. Remove the automatic transmission cooler lines. Refer to Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L60-E/4L65-E/4L70-E transmissions or Transmission Fluid Cooler Hose/Pipe Quick-Connect Fitting Disconnection and Connection for the 4L80-E/4L85-E transmissions.
  11. Remove the engine oil cooler lines. Refer to Engine Oil Cooler Pipe/Hose Quick Connect Fitting .
  12. Remove the engine oil fill tube. Refer to Oil Filler Tube Replacement .
  13. Remove intake manifold tube. Refer to Intake Manifold Tube Replacement (LMM) .
    14. Fig 3: View Of Fan Shroud
    GM834218Courtesy of GENERAL MOTORS CORP.
  14. Remove the upper radiator baffle.

    Remove the fan shroud bolts (1) from the top of the radiator support.

  15. Remove the fan shroud bolts (3) from the sides of the fan shroud.
    16. Fig 4: Identifying Radiator Mounting Bolts
    GM1726332Courtesy of GENERAL MOTORS CORP.
  16. Remove the radiator mounting bolts from the charged air cooler.
  17. Remove the charge air cooler bolts to core support.
  18. Remove the radiator and charge air cooler as assembly.
  19. Remove radiator bolts to charge air cooler.
  20. Remove the radiator insulators.
  21. Inspect the following components:
    • The radiator
    • The insulators
    • The hoses and clamps
    • The mounting hardware

      Replace the components as necessary.

RENDER: 1.0x

NO RELATED

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When to See a Mechanic

Stop DIY work and contact a certified mechanic immediately if any of the following apply:

  • • You smell fuel, burning insulation, or see smoke.
  • • Brakes feel soft, pull hard to one side, or make grinding noises.
  • • The engine overheats, stalls repeatedly, or misfires under load.
  • • You are missing required tools, torque specs, or safe lifting equipment.
  • • You are not confident in the next step or safety outcome.